Wind Blade Research Articles

Evaluating priority strategies for decarbonising offshore wind turbine blades through lifecycle assessment

Abstract While offshore wind is at the early stage of expansion, global capacity is expected to increase rapidly, reaching 330 GW by 2031. This work uses lifecycle assessment (LCA) to evaluate the opportunity for offshore wind energy decarbonisation through wind blade sustainable developments. The findings from the LCA are used to give informed recommendations towards priority areas of development across the blade lifecycle, that are critical to accelerate the sector’s transition towards net-zero targets. The production of raw materials was found to be the largest contributor to cradle-to-gave global warming potential (GWP). The sector should prioritise the utilisation of more sustainable materials, with an emphasis on the decarbonisation of carbon fibre production. Waste produced during blade manufacturing alone accounts for 10% of the blade’s GWP; therefore, increasing the material efficiency in this phase of the lifecycle is a significant opportunity for blade decarbonisation and should be a focus for the sector going forward. O&M was found to be the second largest contributor to GWP, with full decarbonisation of O&M practices potentially realising an 8% reduction in GWP. A range of alterative blade material scenarios were analysed, finding that recyclable resin systems have the greatest potential to decarbonise offshore blades. There are currently no commercial recycling operations for these resins therefore scale up of the recycling technologies is needed before they can be recycled in practice. Additionally, the development of low impact, economically viable circular solutions for legacy blade waste must be an immediate priority for the wind energy sector, given the anticipated exponential growth in global wind turbine blade waste generation. Graphical abstract

Static analysis of wind blades based on weight loads to the gravitation and the centrifugal forces Using Finite Element

Static analysis of wind turbine blades that convert kinetic energy using wind to electrical power has been analyzed using Ansys model. The geometry was imported in ANSYS workbench 2020R1, where the material was changed to Epoxy E-Glass Wet. The mesh independence that occurred at 800 and 600 element sizes and an element size of 800 was chosen for subsequent static analysis. The static analysis shows that the total deformation and von Mises stress of the wind turbine blade was improved at both the vertical position and the horizontal position by 40.0% and 38.61%, respectively. Besides, the static analysis showed an almost linear mode shape increased from mode lines. Nevertheless, Campbell's diagram showed that resonance vibration occurred at an amplitude of 5.5x106Pa with a corresponding frequency of 5Hz, which gave a rotational speed of 262.4x106 rpm. This shows that the impulse force is better applied in wind turbine blade transient analysis at a lower von Mises stress to attain a quicker damping response steady-state, which favors wind turbine blade analysis. Overall, the wind turbine blade is better designed at a vertical position to allow better deformation stress at a static position. Conversely, the von Mises stress showed 44.64% and 38.61% at horizontal and vertical positions. This also agrees with static total deformation, since stress is better managed at a lower percentage range.

CFD simulation and experimental investigation of a Magnus wind turbine with an improved blade shape

With the advancement of technology and growing concern for environmental issues, the demand for energy derived from renewable sources is expected to increase. It is well established that traditional bladed wind turbines exhibit inefficiency in low wind speed conditions. To address this, Magnus wind turbines, featuring cylindrical blades, have been developed specifically for regions with predominantly low-speed winds. However, these turbines present a significant drawback, as they require electric drives to rotate the blades. This study aims to conduct a three-dimensional numerical and experimental investigation of the aerodynamics around a wind turbine with a geometrically complex blade design. The scientific contribution of this work lies in the introduction of a deflector to the cylindrical blades, intended to eliminate the need for an electric drive to initiate blade rotation. A laboratory prototype of a wind turbine with the proposed blade configuration was constructed, and numerical simulations were performed using Ansys Fluent, based on the Reynolds-averaged Navier—Stokes (RANS) equations. The results demonstrate that the turbine's power coefficient (Cp) is approximately 20 % higher than that of traditional Magnus wind turbines. These findings underscore the enhanced efficiency provided by the addition of a deflector to the cylindrical blades.

LiDAR-Based Unmanned Aerial Vehicle Offshore Wind Blade Inspection and Modeling

The deployment of offshore wind turbines (WTs) has emerged as a pivotal strategy in the transition to renewable energy, offering significant potential for clean electricity generation. However, these structures’ operation and maintenance (O&M) present unique challenges due to their remote locations and harsh marine environments. For these reasons, it is fundamental to promote the development of autonomous solutions to monitor the health condition of the construction parts, preventing structural damage and accidents. This paper explores the application of Unmanned Aerial Vehicles (UAVs) in the inspection and maintenance of offshore wind turbines, introducing a new strategy for autonomous wind turbine inspection and a simulation environment for testing and training autonomous inspection techniques under a more realistic offshore scenario. Instead of relying on visual information to detect the WT parts during the inspection, this method proposes a three-dimensional (3D) light detection and ranging (LiDAR) method that estimates the wind turbine pose (position, orientation, and blade configuration) and autonomously controls the UAV for a close inspection maneuver. The first tests were carried out mainly in a simulation framework, combining different WT poses, including different orientations, blade positions, and wind turbine movements, and finally, a mixed reality test, where a real vehicle performed a full inspection of a virtual wind turbine.

Process optimization and economic estimation of nitric acid dissolution for recycling waste wind blades

With the widespread retirement of wind turbines, many discarded waste wind blades have been generated, and how to handle them efficiently has become a critical issue. This study investigated the dissolution of discarded waste wind blades with nitric acid (HNO3) by varying acid concentration, reaction time, temperature, and HNO3 volume. Based on a series of single-factor experiments, the optimal conditions for low energy and acid consumption were determined, and the separation rate of resin reached 95%. As the cost-benefit analysis results suggested, an economic method to recycle a variety of high-value products was achieved. Furthermore, the implementation of a continuous chemical decomposition strategy for multi-batch processing significantly minimized acid consumption, resulting in a further reduction in recycling costs. This work provided an economically and technologically feasible way for recycling materials from decommissioned wind turbines, in order to answer the challenge of emerging solid waste management.

Intelligent Monitoring and Optimization of Wind Turbine Operation Status on Basis of Vibration Signals

In response to the large monitoring errors and incomplete consideration of fault locations in the operation status of wind turbines, this paper combined vibration signals and used a model constructed using nonlinear state estimation technology (NSET) to monitor and optimize the operation status of wind turbines. Firstly, it collected relevant SCADA (supervisory control and data acquisition) and vibration sensor data of Unit 5 of Guangdong Yangjiang Shaba Offshore Wind Farm on site, and used wavelet transform to denoise the vibration signal. Then, full consideration can be given to the faulty parts such as wind blades and gearboxes, and a model constructed by NSET using Markov distance to construct a process memory matrix can be used to monitor the status of the wind turbine equipment. Finally, the multi-level fuzzy comprehensive evaluation method can be used to optimize the comprehensive evaluation of the operating status of wind turbines, reducing monitoring errors.

Effect of process parameters on the mechanical performance of fusion-joined additively manufactured segments

Purpose Herein, the authors report the effects of printing parameters, joining method, and annealing conditions on the structural performance of fusion-joined short-beam sections produced by additive manufacturing. Design/methodology/approach The authors first identified appropriate printing parameters for joining segmented short beams and then used those parameters to print and fusion-join segments with different configurations of stiffeners to form a longer section of a wing or small wind turbine blade structure. Findings It was found that the beams with three lateral and three base stiffening ribs give the highest flexural strength among the three beams investigated. Results on joined beams annealed at different conditions showed that annealing at 70 °C for 0.5 h yields higher performance than annealing at the same temperature for longer times. It is also found that in the case of the hot-plate-welded three-dimensional (3D)-printed structures, no annealing is needed for reaching a high strength-to-weight ratio, but annealing is helpful for maximizing the modulus-to-weight ratio. Both thermal buckling and edge wrapping were observed under annealing at 70°C for 0.5 h for 3D-printed beams comprising two lateral and four base stiffening plates. Originality/value Fusion-joining of additively manufactured segments is needed owing to the constraint in building volume of a typical commercial 3D-printer. However, study of the effect of process parameters is needed to quantify their effect on mechanical performance. This investigation has therefore identified key printing parameters and annealing conditions for fusion-joining short segments to form larger structures, from multiple 3D-printed sections, such as wind blade structures.

A Comparison of a Three Blade and Five Blade Wind Turbine in Terms of the Mechanical Properties Using the Q-Blade Software

يمكن لتوربينات الرياح المنتشرة في مزارع الرياح على نطاق المرافق أن تدعم تلبية رغبات الطاقة المستقبلية وتقليل انبعاثات ثاني أكسيد الكربون عن طريق تقليل متطلبات الطاقة من الوقود الأحفوري. مع ارتفاع درجة حرارة الهواء على مدار اليوم، تزداد سرعة الرياح بسبب تدرجات درجة الحرارة، والتي تنتج تدرجًا في الكثافة / الضغط، مما يؤدي إلى حركة الهواء التي تواجهها توربينات الرياح. اعتمادًا على تضاريس الأرض، يمكن أن تواجه الرياح وتوجه في الوديان بين التلال وفوقها حيث تتدفق وتتبع منحنيات الأرض. تنتج هذه التضاريس زيادة في سرعة الرياح في القمم والتلال. في هذا العمل، تم تصميم شفرة دوار توربينات الرياح الأفقية الصغيرة للعمل في ظل سرعة الرياح المنخفضة، باستخدام برنامج (Q-Blade). استنادًا إلى نظرية عنصر الشفرة (BEM). مع الجنيح NACA3712. تم استخدام دوار ثلاثي الشفرات ودوار بخمس شفرات بناءً على نوع التوربين وحجم الدوار لتوليد الطاقة الميكانيكية من طاقة الرياح. تم إجراء مقارنة وتحليل قوة التوربين ومعامل القدرة ومعامل عزم الدوران عند سرعة رياح منخفضة ((1m/s-8m/s وتم الحصول على نتائج دقيقة للغاية. وجد أن أفضل أداء يمكن أن يعمل فيه دوار توربيني ثلاثي الشفرات بقدرة توربينية تبلغ (955W) كما تم الحصول على قدرة التوربين ((582W للدوار خماسي الشفرات. وجد أن تصميم توربينة رياح أفقية صغيرة بخمس ريش أفضل من التوربين بثلاث ريش ومناسب للعمل في المناطق ذات سرعة الرياح المنخفضة وبكفاءة عالية مقارنة بحجم التوربين.

Investigating the Structural and Power Performance of a 15 MW Class Wind Energy Generation System under Experimental Wind and Marine Loading

The global transition to renewables in response to climate change has largely been supported by the expansion of wind power capacity and improvements in turbine technology. This is being made possible mainly due to improvements in the design of highly efficient turbines exceeding a 10 MW rated power. Apart from power efficiency, wind turbines must withstand the mechanical stress caused by wind–hydro conditions. Such comprehensive structural analysis has rarely been performed previously, especially for large-scale wind turbines under real environmental conditions. The present work analyzes the energy production and structural performance of an NREL-IEA 15 MW wind turbine using measured wind and hydro data. First of all, an optimum operating range is determined in terms of the wind speed and blade pitch angle to maximize the power coefficient. Then, at this optimum range, a detailed breakdown of the forces and moments acting on different components of the wind turbine is presented. It was found that wind speeds of 9 to 12 m/s are best suited for this wind turbine, as the power coefficient is at its maximum and the mechanical loads on all components are at a minimum. The loads are at a minimum due to the optimized blade pitch angle. The bending force on a monopile foundation (fixed on the seabed) is found to be at a maximum and corresponds to nearly 2000 kN. The maximum blade force is nearly 700 kN, whereas on the tower it is almost 250 kN. The maximum force on the tower occurs at a point which is found to be undersea, whereas above-sea, the maximum force on the tower is nearly 20% less than the undersea maximum force. Finally, seasonal and annual energy production is also estimated using locally measured wind conditions.

Manufacture and testing of biomass-derivable thermosets for wind blade recycling.

Wind energy is helping to decarbonize the electrical grid, but wind blades are not recyclable, and current end-of-life management strategies are not sustainable. To address the material recyclability challenges in sustainable energy infrastructure, we introduce scalable biomass-derivable polyester covalent adaptable networks and corresponding fiber-reinforced composites for recyclable wind blade fabrication. Through experimental and computational studies, including vacuum-assisted resin-transfer molding of a 9-meter wind blade prototype, we demonstrate drop-in technological readiness of this material with existing manufacture techniques, superior properties relative to incumbent materials, and practical end-of-life chemical recyclability. Most notable is the counterintuitive creep suppression, outperforming industry state-of-the-art thermosets despite the dynamic cross-link topology. Overall, this report details the many facets of wind blade manufacture, encompassing chemistry, engineering, safety, mechanical analyses, weathering, and chemical recyclability, enabling a realistic path toward biomass-derivable, recyclable wind blades.

Cohesive zone modeling of the buckling behavior of a fusion-joined, additive-manufactured wind blade

Cohesive zone modeling of the buckling behavior of a fusion-joined, additive-manufactured wind blade

How to Perform a Statistical Analysis of Non-Destructive Degradation Data to Study Crack Growth in Wind Blades as a Function of the Number of Cycles

Objective: The aim of this paper is to show the application of the Exponential Regression Model to study the failure time of a system over time. The data was taken from the paper (Wang et al., 2021). Theoretical framework: The linear regression model, where the response is associated with the explanatory variables by means of a linear model, is the best known. To formulate the model, it is necessary to specify a deterministic component and a random (stochastic) component. The exponential model should be used when it is assumed that risk is constant over time. Once the model has been specified, its parameters are estimated. In the absence of normal errors and especially in the presence of censoring, a more appropriate option is the maximum likelihood method. As the equations are non-linear in their parameters and do not have an analytical solution, it is necessary to use the Newton-Raphson numerical method. Due to the simplicity of the exponential regression model, few situations in practice are adequately adjusted by this model. The Weibull regression model is widely used in survival analysis (Bastos Lyra et al., 2008) Method: Data taken from the article (Wang et al., 2021) e foi utilizado a Regressão Exponencial para modelar os dados. Final Considerations: This result indicates that Exponential Regression is a very viable option when the aim is to monitor the number of cracks as a function of time to check whether a system will fail. In this specific Case Study, it is clear that one of the blades is better than the others and that there are some Probability Distribution models that are suitable for the model. Implications of the research: The use cases of Exponential Regression are more restricted in the scientific literature and because of this, this case study is interesting to show that this model is effective for treating data in the area of reliability. Originality/value: Despite being a well-known statistical tool, Exponential Regression has a specific application in monitoring the number of cracks over time in a system.

Exploratory Study on the Application of Graphene Platelet-Reinforced Composite to Wind Turbine Blade.

With the growth of the wind energy market and the increase in the size of wind turbines, the demand for advanced composite materials with high strength and low density for wind turbine blades has become imperative. Graphene platelets (GPLs) stand out as highly premising reinforcements due to their exceptional physical properties, resulting in their widespread adoption in the composite industry in recent years. The present study aims to analyze the applicability of a graphene-platelet-reinforced composite (GPLRC) to wind turbine blades in terms of structural performance. A finite element blade model is constructed by referring to the National Renewable Energy Laboratory (NREL) 5 MW wind turbine, and its reliability is verified through a convergence test. The performance of the wind turbine blade is quantitatively examined in terms of the deflection and stress, natural frequencies, and twist angle. The applicability of the GPL-reinforced wind blade is explored through a comparison with wind blades manufactured with glass fiber and carbon nanotubes (CNTs). The comparison indicates that the performance of a wind blade can be remarkably improved by reinforcing with GPLs instead of traditional fillers, and the weight of not only the wind blade itself but also the wind turbine system can be remarkably reduced. The present results can be useful in the development of next-generation high-strength lightweight wind turbine blades.

Synthesis of geopolymer using glass fiber powder from retired wind blades: A new attempt to recycle solid waste in wind power industries

This study explores the potential of recycling and utilizing discarded wind turbine blades. It proposes a new method that upcycles the glass fiber powder (GFP) in these blades into geopolymer gel, offering a new solution for the recycling and treatment of retired wind blades. Analyses of the X-ray diffraction (XRD) pattern of the GFP raw material and its dissolution in concentrated alkali indicate a large content of vitreous and active silica-aluminum, suggesting its suitability for producing geopolymers through alkali activation. The effects of the alkali activator modulus (Ms), alkali-binder ratio (N/B), and water-binder ratio (w/b), raw material particle size, and initial curing temperature on the compressive strength of the specimens were comprehensively and systematically investigated. The reaction behavior, chemical structure, and microstructure of GFP-synthesized geopolymers were characterized by selective dissolution, microcalorimetry, Fourier transform infrared spectroscopy (FTIR), X-ray diffraction (XRD), and scanning electron microscopy equipped with energy dispersive spectroscopy (SEM-EDS). The results showed that gels were formed by the geopolymerization reaction between the GFP and alkali activator. The compressive strength of the specimens increased first and then decreased with increasing alkali activator Ms and N/B. However, increasing w/b led to a decrease in strength. Appropriately small particle sizes of the raw material and moderately increasing the initial curing temperature are beneficial to strengthen the compressive strength. The optimal 28 days compressive strength of 43.43 MPa was achieved with an activator Ms of 1.4, N/B of 10 %, w/b of 0.33, GFP with a D90 of 170 mesh, and an initial 24 h curing temperature of 60 °C. The results of this study can promote the utilization of waste wind blades in the production of sustainable building materials.

Valorization of Biomass and Industrial Wastes as Alternative Fuels for Sustainable Cement Production

The cement industry contributes around 7% of global anthropogenic carbon dioxide emissions, mainly from the combustion of fuels and limestone decomposition during clinker production. Using alternative fuels derived from wastes is a key strategy to reduce these emissions. However, alternative fuels vary in composition and heating value, so selecting appropriate ones is crucial to maintain clinker quality and manufacturing processes while minimizing environmental impact. This study evaluated various biomass and industrial wastes as potential alternative fuels, characterizing them based on proximate analysis, elemental and oxide composition, lower heating value, and bulk density. Sawdust, pecan nutshell, industrial hose waste, and plastic waste emerged as viable options as they met the suggested thresholds for heating value, chloride, moisture, and ash content. Industrial hose waste and plastic waste were most favorable with the highest heating values while meeting all the criteria. Conversely, wind blade waste, tire-derived fuel, and automotive shredder residue did not meet all the recommended criteria. Therefore, blending them with alternative and fossil fuels is necessary to preserve clinker quality and facilitate combustion. The findings of this research will serve as the basis for developing a computational model to optimize the blending of alternative fuels with fossil fuels for cement production.

Experimental campaign for the characterization of precipitation in a complex terrain site using high resolution observations

Precipitation has an effect on wind power at several levels. It affects the wind current, blade status, wake development and power production. Power production is affected by the harmful effect of precipitation on the blades eroding its surface and altering their aerodynamic performance. In the past decades, wind has been characterized using different techniques, but less effort has been devoted to precipitation measurement. In this work, the results of an experimental campaign performed at a high altitude complex terrain site to characterize precipitation using high resolution observations are presented. The campaign, carried out at CENER’s experimental wind farm (Alaiz) during 2023 within the framework of the Horizon Europe AIRE project, lasted nine months and different precipitation types (rain, snow, graupel) were recorded using a Micro Rain Radar (MRR), a Parsivel disdrometer and a rain gauge co-located with an instrumented wind mast with anemometers and wind vanes at different heights. Two case studies are selected to illustrate the wide range of variability found in precipitation conditions, particularly during the cool season. Precipitation characterization is very challenging at high temporal resolution, making necessary measurement campaigns with different precipitation equipment to optimize their performance and optimise its calibration. The study of precipitation profiles with MRR will support the study of precipitation impingement on wind turbine blades responsible of blade erosion. Moreover, these measurements will contribute to create the link between in-field wind farm data, laboratory experiments in rain erosion test rig and blade damage models necessary to improve wind turbine and wind farm design and operation.

A self-regulation blades wind energy harvester system for self-powered wireless monitoring sensors

Using wind energy in the natural environment provides a promising solution for wireless sensor power supply for ecological, meteorological, environmental, and infrastructure monitoring. However, the uncertainty and disorder of natural wind restrict the further development of wind energy harvester systems and self-powered wireless sensor technology. Hence, this paper proposes a self-regulation blade wind energy harvester system (SBWEHS) for self-powered wireless monitoring sensors in remote field areas with power shortages. The system is mainly composed of three parts: wind harvesting mechanism, generator module, and energy storage module. The device can control the blade overlap ratio according to the wind speed while generating electricity to maximize the power coefficient. The system can control the blade’s closure in bad weather to protect the device. Based on the computational fluid dynamics technology of Ansys Fluent software, this study evaluated the impact of wind speed and blade overlap ratio on the two-stage blades. Experiments revealed that when the overlap ratio of the blades is fixed at 0.2 and the wind speed is set at 16 m/s, the maximum average power will reach 0.79 W, which fulfills the power requirements of wireless sensors. These results illustrate that the SBWEHS can effectively supply power for wireless monitoring sensors, especially in remote natural environments.

Lessons learned from the sustainable recycling process of a wind blade made with a new thermoplastic resin

The use of thermoplastic resins instead of thermoset ones in wind turbine blade manufacturing is being investigated and validated in a global scale due to some theoretical improvements such as costs saving during production, shorter cycle’s time and a better circular recovery of the raw materials at the End of Life. The initial objective of this paper was to manufacture and test a small wind turbine blade (SWTB) glass fiber-reinforced thermoplastic (GFRT) resin composites, recycle it, and use the products obtained from the recycling process (fibers and resin) to remanufacture a new thermoplastic SWTB. But loss of fibers higher than estimated during the recycling process made to get away from the original aim of testing both blades (1st and 2nd recyclable blades). At least, some lessons learned were obtained to improve future developments. Nevertheless, this study provides an example of how to recycle a small WT blade and to remanufacture it using the same raw materials.

3D printing wind turbine tooling

Using one of the world’s largest 3D printers to produce wind blade tooling.

Verification of Euler–Bernoulli beam theory model for wind blade structure analysis

This paper presents a computational tool for analyzing the structural response of wind turbine blades using the advanced Euler–Bernoulli Beam theory. The objective is to achieve efficient computation of blade structural response under aerodynamic loading without sacrificing computational accuracy. This study involves the development of a Python-based computer program as a numerical tool, which utilizes inputs such as blade geometry and aerodynamic loading from Blade Element Momentum theory. The program outputs axially varying moments of inertia, spatial deflections of the blade, and stress distributions within the blade. The numerical tool is verified by comparing the results with both analytical solutions and far more time-consuming commercial finite element solvers. One of the key contribution of this research is the application of the polygon algorithm, which efficiently calculates the moments of inertia of web-stiffened turbine blades along the blade length. It is shown herein that this algorithm significantly reduces computational time while maintaining numerical accuracy as compared to the results obtained from commercially available finite element codes. The study confirms that the advanced Euler–Bernoulli beam theory, when combined with the polygon algorithm, is capable of accurately predicting the structural response of cambered and twisted wind turbine blades during the initial design phase.